Service Manual

1 spicer Tandem Drive AxlesService ManualSingle Reduction & Single Reduction withWheel Differential LockAXSM-0046 July 2016 DDH/RDH40 DSH/RSH40 DSP/RSP40 DST40(P)DDT41(P)DSP/RSP41 DST41(P)DDH/RDH44 DSH/RSH44DA/RA344DS/RS344DA/RA404(P)DD/R D404DS/RS404(P) DA/EA405(P) DD/RD405 DS/RS405(P)DD/RD454DS/RS454(P)This symbol is used throughout this Manual to call attention to procedures where care-lessness or failure to follow specific instruc-tions may result in personal injury and/or component from the instructions, choice of tools, materials and recommended parts mentioned in this publication mayjeopardize the personal safety of the Service technician or vehicle : Failure to follow indicated proce-dures creates a high risk of personal injury to the servicing : Failure to follow indicated pro-cedures may cause component damage or : Highly recommended proce-dures for proper Service of this.

2 Additional Service information not covered in the Service : Helpful removal and installation proce-dures to aid in the Service of this use genuine spicer replacement description and specifications contained in this ser-vice publication are current at the time of printing. Dana reserves the right to discontinue or to modify its models and/or procedures and to change specifications at any time without reference to brand names in this publication is made simply as an example of the types of tools and materials recommended for use and should not be considered an endorsement.

3 Equivalents, if available, may be InformationImportant NoticeGeneral Information General Information .. i Introduction .. 1 Model Listing .. 1 Model 1 Model Identification .. 2 Part 2 Ring Gear and Pinion .. 3 Inspection Failure Analysis .. 4 Prepare the Parts for Inspection .. 5 Inspection .. 6 Check Input Shaft End-play (Forward Axle) .. 7 Check Output Shaft End-play (Forward Axle)..7 Remove Differential Carrier Differential Carrier Assembly - 8 Remove Differential Carrier (Forward and Rear).. 9 Install Differential Carrier Install Differential Carrier (Forward and Rear).

4 10 Differential Lockout Inter-Axle Lockout Types .. 11 Remove Lockout .. 14 Install Lockout .. 14 Power Divider Power Divider - Parts Exploded View .. 15 UNITS BUILT BEFORE 11/2/1998 .. 16 Remove Power Divider .. 16 Disassemble, Assemble, and Overhaul Power Divider .. 17 Remove Lube Pump .. 21 Install Lube Pump .. 21 Install Power Divider to Carrier Assembly .. 22 UNITS BUILT AFTER 11/2/1998 .. 24 Disassemble, Assemble, and Overhaul Power Divider (In Vehicle) .. 24 Lube Pump Removal: Assemblies Built Before June 15, 2008.

5 27 Lube Pump Installation: Assemblies Before June 15, 2008 .. 27 Lube Pump Removal: Assemblies Built After June 15, 2008 .. 28 Lube Pump Installation: Assemblies After June 15, 2008 ..29 Lube Manifold Removal .. 31 Manifold Installation .. 31 Hose/ Filter Assembly .. 32 Install Power Divider to Carrier Assembly (In Vehicle) .. 33 Disassemble, Assemble, and Overhaul Power Divider (Out of Vehicle) .. 36 Lube Pump Removal: Assemblies Built Before June 15, 2008 .. 40 Lube Pump Installation: Assemblies Built Before June 15, 2008.

6 40 Lube Pump Removal: Assemblies Built After June 15, 2008 .. 41 Lube Pump Installation: Assemblies Built After June 15, 2008 .. 42 Lube Manifold Removal ..43 Manifold Installation ..43 Hose/ Filter Assembly ..44 Install Power Divider to Carrier Assembly (Out of Vehicle) .. 45 Measure and Adjust Input Shaft Assembly Carrier Assembly - Parts Exploded View ..49 Disassemble Carrier Assembly ..49 Drive Pinion Front Axle Pinion Assembly-Parts Exploded 53 Rear Axle Pinion Assembly-Parts Exploded 53 Disassemble and Overhaul Drive Pinion.

7 54 Replace Pinion Bearing Cage Cups .. 56 Adjust Pinion Bearing Preload .. 57 Final Buildup .. 58 Install Drive Pinion Assembly .. 61 Wheel Differential Assembly Wheel Differential - Parts Exploded View ..63 Disassemble, Overhaul and Assemble Wheel Differential (Forward and Rear Axles) ..64 Overhaul and Assemble Wheel Differential ..65 Measure and Adjust Carrier Assembly ..67 Change Backlash Setting ..68 Measure Ring Gear Runout ..68 Adjust Tooth Contact Pattern Adjust Ring and Pinion Tooth Contact Pattern ..69 Adjust Pinion Position ..70 Adjust Ring Gear Position (Backlash).

8 70 Wheel Differential Lock Wheel Differential Lock - Parts Exploded View ..71 Install and Adjust Wheel Differential Lock ..72 Install and Adjust Ring Gear Thrust Bolt ..73 Table of ContentsTable of ContentsHousing and Output Shaft Assembly Remove Output Shaft Assembly ..74 Housing and Output Shaft Assembly - Parts Exploded View ..75 Overhaul and Assemble Output Shaft Assembly ..76 Measure and Adjust ..78 Seals Replace Seal ..79 Guidelines for Reusing Yoke ..79 Service Kit 217414 ..80 New Welded D-Housing Cover ..80 IASS Inter-Axle Speed Sensor - Parts Exploded View.

9 81 Disassemble Inter-Axle Speed Sensor ..82 Overhaul Inter-Axle Speed Sensor ..82 Install Inter-Axle Speed Sensor ..83 Housing Breather Install New Axle Housing Breather (Metal and Plastic) .. 84 Wheel End Seal Wheel End Seal - Parts Exploded View .. 85 Remove and Overhaul Wheel End Seal ..86 Install Wheel End Seal ..86 Wheel Adjustment Systems Adjust Wheel Bearing .. 87 Wheel End Verify Wheel End-play Procedure .. 89 Readjust Wheel End-play Procedure .. 89 Lubricate Wheel End .. 90 Wheel Ends Without Oil Fill Hole .. 91 Lubrication General Lubrication Information.

10 92 Approved Lubricants .. 92 Recommendations for Viscosity / Ambient Temp.. 92 Lube Change Intervals .. 93 Change Lube .. 94 Standpipes .. 95 Final Check .. 96 Towing Proper Vehicle Towing .. 97 Theory of Operation Power Divider Operation (Power Flow and Torque Distribution) .. 98 Operate Wheel Differential Assembly .. 100 Control Systems for Differential Lock .. 100 Wheel Differential Lock .. 101 Parts Identification Power Divider - Parts Exploded View .. 103 Front Drive Axle - Parts Exploded View ..104 Rear Drive Axle - Parts Exploded View.